Modular liquid reservoir

ABSTRACT

A modular liquid reservoir comprises a plurality of shell sections that in an assembled state define a fluid tight reservoir volume. Each shell section includes a plurality of flow apertures that are adapted to fixedly engage a variety of interchangeable, insertable attachments.

BACKGROUND OF THE INVENTION

The invention relates to a liquid storage reservoir having a modular construction.

Automobiles use a variety of liquid-containing systems for efficient operation. For example, closed-loop liquid coolant circulation systems are used in conjunction with vehicle engines to dissipate heat that is created during normal operation of the engine. Such coolant circulation systems typically include a pressurized coolant reservoir and may further include an overflow reservoir. The overflow reservoir, if provided, can accommodate excess liquid coolant that is generated due to thermal expansion of the coolant supply during periods of elevated engine and/or ambient temperature. An overflow reservoir can also be used to add fluid to or remove fluid from the coolant circulation system. In addition to coolant circulation systems, vehicles may use other liquid-containing systems, e.g., an automatic windshield washing system that includes a reservoir for storing washer fluid.

In these liquid-containing systems, in order to facilitate flow of liquid between a respective reservoir and the remainder of the system, the reservoir will typically include at least one outlet aperture that may be disposed at a lower portion of the reservoir such that the system is gravity fed. Likewise, liquid reservoirs are typically provided with at least one inlet aperture that allows liquid to be added to the reservoir. The inlet and outlet apertures typically comprise fittings to form a sealed fluid connection between the reservoir and the remainder of the system. In addition to the inlet and outlet apertures, further apertures may be provided that cooperate with monitoring equipment to measure a condition of the contents of the reservoir.

In order to efficiently incorporate the various liquid-containing systems into a vehicle, the liquid reservoirs must conform to a variety of design considerations. The design considerations, which may impose physical or geometric constraints, may be different for different vehicle makes and models, and typically encompass variables such as the volume and shape of the reservoir, the number, type and position of the attendant inlet(s) and outlet(s), and the incorporation of mounting hardware.

Due to the large number of possible combinations of design criteria facing automobile manufacturers, it would be advantageous to provide a liquid reservoir for a liquid-containing system having a modular construction whereby automakers could select from a variety of stock parts and assemble with relative ease a liquid reservoir having the desired functionality, geometry, etc.

SUMMARY OF THE INVENTION

It is a primary object of the invention to provide a liquid reservoir having an easily modifiable configuration and/or capacity.

Another object of the invention is to provide a liquid reservoir constructed from a plurality of shell sections, each shell section having formed therein a plurality of apertures adapted to engage a variety of functional attachments.

A further object of the invention is to provide a modular liquid reservoir constructed from a plurality of versatile, interchangeable, relatively inexpensive components.

Disclosed is a modular liquid reservoir comprising a plurality of shell sections which when assembled along annular mating surfaces define a fluid tight reservoir volume. Generally, an assembled reservoir includes a pair of end cap shell sections and one or more optional expansion shell sections. Each end cap shell section includes one annular mating surface, while each expansion shell section includes two annular mating surfaces. Each shell section further includes a plurality of apertures that are each adapted to fixedly engage an attachment member.

These and other features of preferred embodiments of the invention, in addition to being set forth in the claims, are also disclosed in the specification and/or in the drawings, and the individual features each may be implemented in embodiments of the invention either individually or in the form of subcombinations of two or more features and can be applied to other fields of use and may constitute advantageous, separately protectable constructions for which protection is also claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described in further detail hereinafter with reference to illustrative preferred embodiments shown in the accompanying drawings in which:

FIG. 1 shows an assembled modular reservoir according to a first embodiment.

FIG. 2 shows an end cap shell section having a variety of attachment members joined thereto.

FIG. 3 shows an assembled modular reservoir according to a second embodiment.

FIG. 4 shows an expansion shell section having a plurality of attachment members joined thereto.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

An assembled reservoir according to one embodiment is shown in FIG. 1. The reservoir 100 includes a pair of end cap shell sections 110, 120. The shell sections are preferably formed from a synthetic resin material and comprise an interior region having a substantially circular or oval cross section. Adjacent shell sections in an assembled reservoir are axially aligned and connected with each other along complimentary annular mating surfaces formed at one end of each shell section. End cap shell sections 110, 120 are joined along shared interface 130 to form the reservoir volume therebetween. As illustrated, end cap shell section 110 is hot plate welded to end cap shell section 120 via weld flanges 115, 125 to form a permanent bond along interface 130. The annular mating surfaces are adapted to provide a fluid tight seal between joined shell sections.

First end cap shell section 110 has an interior region having a first volume (V1), and second end cap shell section 120 has an interior region having a second volume (V2) such the total reservoir volume is approximately equal to V1+V2. As illustrated in FIG. 1, V1<V2. The volumes of the shell sections used to form a reservoir may be equal or unequal. Advantageously, the volumes of the shell sections can be selected in order to satisfy the shape and total volume requirements of the reservoir. Preferred end cap shell sections each have a volume ranging from about 0.5 to 3.5 liters (e.g., 0.5, 1, 1.5, 2, 2.5, 3 or 3.5 liters).

The connection between adjacent shell sections is preferably formed using known synthetic resin welding techniques such as hot plate welding, sonic welding, spin welding, or vibratory welding. These resin bonding techniques create substantially permanent bonds such that the shell sections, once joined, are not readily separable.

Other joining methods can be used such that the joined parts are readily separable. Such methods include snap-on, screw-on, or dovetail connections or using one or more fastening members such as clamps or bolts, preferably in connection with a seal forming member such as an O-ring that is disposed between mating surfaces.

According to one embodiment, the fastening member used to connect adjacent shell sections comprises a circumferential clamp that cooperates with a pair of radially-extending flanges formed at the outer circumference of each mating surface. The flanges can be comprise a bevel along a non-mating axial surface thereof such that hoop stress provided by the clamp operates to forcibly engage aligned shell sections in an axial direction and form a fluid tight seal along the mating surfaces.

As an alternative to providing a clamp, holes formed through mating flanges and in axial alignment with one another can receive fastening elements, e.g., bolts, that secure adjacent shell sections. Regardless of the fastening member used to join adjacent shell sections, the mating surfaces form a substantially circular or oval seal surface extending 360° about the circumference of the reservoir.

Each shell section further includes a plurality of apertures adapted to fixably engage an attachment member. The apertures are formed in an outer wall of the shell section and provide a conduit between the outside of the assembled reservoir and the inside of the assembled reservoir.

Still referring to FIG. 1, reservoir 100 includes a plurality of attachment members. The attachment members are preferably formed from a synthetic resin material and, in a preferred embodiment, are hot plate welded over a respective aperture formed in one of the shell sections. The above mentioned joining methods can also be used to join an attachment member to a shell section.

The attachment members include flow attachments such as fillnecks, nipples, and the like, and non-flow attachments such as attachments adapted to include monitoring apparatus such as a level sensor, thermometer, pH probe, and the like. An attachment member can also comprise a stopcock attachment that permanently or temporarily closes the aperture. As shown, joined to end cap shell 110 are nipple attachment 140 and fillneck attachment 150. Joined to end cap shell 120 is nipple attachment 160.

Each attachment member comprises a base section having a mating surface for joining with a cooperating mating surface formed around the corresponding shell section aperture. Fillneck 150, for example, comprises base section 152 having a weld flange 154. Similarly, nipple attachment 160 comprises base section 162.

According to a preferred embodiment, attachment members can be attached to shell sections in a variety of locations and/or in one of a number of different orientations. For example, nipple attachments are preferably joined to outlet apertures and fillneck attachments are preferably joined to inlet apertures. Other arrangements are possible, however, such as joining a nipple attachment to an inlet aperture.

As illustrated in FIG. 1, nipple 164 of nipple attachment 160 is aligned axially with respect to reservoir 100. In an alternate configuration (shown using broken lines) nipple 164a can be aligned radially with respect to reservoir 100. Advantageously, by allowing post-manufacture assemblage of the shell sections and the attachment members, end users can create liquid reservoirs that substantially conform to governing design criteria.

The attachments can be interchangeable such that a variety of different attachments can be attached to a particular aperture. Because each shell section includes a plurality of apertures each adapted to receive a number of different attachments, the reservoir can be assembled to accommodate a wide variety of design considerations.

A variety of different attachments can be provided. Flow attachments, for example, can have a variety of different dimensions and configurations. Fillnecks can be threaded or provided with a cam-type lock for engaging an external connection. Likewise, the length, diameter and orientation of nipples can be varied. A nipple attachment can comprise one or more nipples, and where multiple nipples are provided, the respective nipples can be configured substantially the same or substantially different from each other.

Selection of the desired shell sections and attachment members permits rapid custom manufacture of a fluid reservoir from preassembled elements. The modular design is especially well adapted for incorporation into the unique designs of various host apparatus such as automobiles wherein reservoirs can be used as coolant reservoirs, overflow reservoirs, washer reservoirs, and the like. The reservoirs can be used to contain pressurized or non-pressurized liquids.

A method of forming the reservoir comprise the steps of joining a plurality of shell sections along annular mating surfaces to define a reservoir volume, and joining a plurality of attachment members to apertures formed in the shell sections.

FIG. 2 is a perspective view of end cap shell section 110 showing the component prior to joining it to a second shell section and prior to joining fillneck 150 to aperture 200. Aperture 200 includes a circumferential mating surface 202 such as a weld flange that is adapted to form a fluid tight seal.

FIG. 2 illustrates how a variety of configurations comprising different attachment members (or attachment members positioned at different locations) can be created. As shown via the inset illustrations, aperture 200 of end cap shell section 110 can have joined thereto a nipple attachment member 210 comprising radially-aligned nipple 214 (FIG. 2 a), a nipple attachment member 220 comprising axially-aligned nipple 224 (FIG. 2 b), or a stopcock attachment member 230 comprising stopcock 234 (FIG. 2 c).

Further illustrating the modular design of the reservoir, FIG. 2 d shows that a nipple attachment member comprising a single nipple 140 can be replaced by a nipple attachment member 240 comprising first and second radially-aligned nipples 242, 244. Optionally, one or more of the nipples 242, 244 could be aligned axially (not shown). Furthermore, the modular design permits the location of the attachment members to be variable. As an alternative, or in addition to nipples 140, 242, 244, an attachment member 250 comprising one or two nipples (252, 254) can be incorporated in end cap member 110 at a different position with respect to the overall reservoir design. Such flexibility allows an end user to position the desired attachment(s) in the desired location(s) with respect to the overall geometry of the reservoir.

An assembled reservoir according to a further embodiment is shown in FIG. 3. The reservoir 300 includes a pair of end cap shell sections 310, 320 and an expansion shell section 350 positioned therebetween. The three shell sections are aligned axially whereby end cap shell section 310 is joined along interface 330 with expansion shell section 350, and end cap shell section 320 is joined along interface 340 with expansion shell section 350.

First end cap shell section 310 has an interior region having a first volume (V1), second end cap shell section 320 has an interior region having a second volume (V2), and the expansion shell section has an interior region having a third volume (V3) such the total reservoir volume is approximately equal to V1+V2+V3. Preferred expansion shell sections each have an individual volume ranging from about 3 to 6 liters (e.g., 3, 3.5, 4, 4.5, 5, 5.5 or 6 liters).

Attachment members can be joined to apertures formed in end cap shell sections and/or expansion shell sections. Various exemplary methods for joining attachment members to shell sections (as well as for joining shell sections to each other) have been described previously.

As illustrated in FIG. 3, adjacent pairs of the shell sections (310, 350 and 320, 350) are hot plate welded to one another and the various attachment members are hot plate welded over a respective aperture to form fluid tight seals between joined components. Joined to end cap shell 310 is nipple attachment 360 having axially-aligned nipple 364. Joined to end cap shell 320 are nipple attachments 370 and 380. Nipple attachment 370 includes axially-aligned nipple 374 and nipple attachment 380 includes radially aligned nipple 384. Also, joined to expansion shell 350 is fillneck attachment 390.

A perspective view of unassembled expansion shell section 350 is shown in FIG. 4. Expansion shell section 350 includes two annular mating surfaces 352, 354 formed respectively in annular weld flanges 353, 355. The shell section also includes attachment member 385 fitted around aperture 380. Attachment member 385 includes weld flange 386 form in an outer circumferential surface thereof and adapted to form a fluid tight seal with fillneck attachment 390. As shown in the inset, as an alternative to attachment member 385, a stopcock attachment 389 can be provided which closes aperture 380.

As also illustrated in FIG. 4, the interior region of expansion shell section 350 has incorporated therein an optional structural reinforcing member 390. The structural reinforcing member comprises a square grid of reinforcing bars that enhance the mechanical rigidity of the shell section.

The foregoing description and examples have been set forth merely to illustrate the invention and are not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed broadly to include all variations falling within the scope of the appended claims and equivalents thereof. 

1. A liquid reservoir comprising: a plurality of shell sections assembled along annular mating surfaces and defining an interior region for storing fluids; and a plurality of attachment members; wherein the annular mating surfaces are formed in an axial end surface of the shell sections and each shell section comprises a plurality of apertures, each aperture adapted to fixably engage a respective one of said attachment members.
 2. The liquid reservoir of claim 1, wherein the interior region has a substantially circular or oval cross section.
 3. The liquid reservoir of claim 1-, wherein the shell sections are formed from a synthetic resin material.
 4. The liquid reservoir of claim 1, wherein shell sections are welded together along a respective pair of annular mating surfaces.
 5. The liquid reservoir of claim 1, wherein shell sections are clamped or bolted together along a respective pair of annular mating surfaces.
 6. The liquid reservoir of claim 5, further comprising a circumferential seal forming member between each respective pair of annular mating surfaces.
 7. The liquid reservoir of claim 1, wherein the attachment members are formed from a synthetic resin material.
 8. The liquid reservoir of claim 1, wherein each attachment member is engaged with a respective one of each aperture using a weld.
 9. The liquid reservoir of claim 1, wherein each attachment member is engaged with a respective one of each aperture using a clamp or a plurality of bolts.
 10. The liquid reservoir of claim 1, wherein the shell sections comprise two end cap shell sections.
 11. The liquid reservoir of claim 1, wherein the shell sections comprise two end cap shell sections and at least one expansion shell sections.
 12. A method of forming a fluid storage reservoir, said method comprising the acts of: joining a plurality of shell sections along annular mating surfaces to define a reservoir volume, and joining a plurality of attachment members to apertures formed in the shell sections, wherein the annular mating surfaces are formed in an axial end surface of the shell sections.
 13. The method of claim 12 wherein the shell sections are made of a synthetic resin and are joined together by hot plate melting.
 14. The method of claim 12 wherein the shell sections and the attachment members are made of a synthetic resin and are joined together by hot plate melting.
 15. A synthetic resin shell section adapted to form a fluid tight reservoir, said shell section comprising at least one annular mating surface formed in an axial end surface thereof, and a plurality of apertures formed in an outer wall of the shell section, each aperture adapted to fixedly engage a synthetic resin attachment member thereto.
 16. The shell section of claim 15, wherein the shell section is an end cap shell section.
 17. The shell section of claim 15., wherein the shell section is an expansion shell section.
 18. The shell section of claim 17, wherein an interior region of the expansion shell section comprises a structural reinforcing member. 